Process for producing fermentation feedstock from extruded cereal material

ABSTRACT

There is disclosed a process for producing a fermentation feedstock from a cereal material that is extruded. The cereal material extrudate is liquefied and separated into streams. Furthermore, of the liquefied extrudate may be saccharified.

This application claims priority of Provisional Application Ser. No.60/397,986 filed Jul. 23, 2002, the entire contents of which areincorporated herein by reference.

FIELD OF INVENTION

The present invention related to a process for producing a fermentationfeedstock.

BACKGROUND

Most corn processed in the United States is treated by the wet millingprocess. This process includes a 24-48 hour chemical steeping of thecorn followed by grinding, filtration, and high-speed centrifugationusing copious amounts of water to separate fiber, germ, protein, andstarch. Traditionally, the germ is subsequently processed to vegetableoil, and the protein and fiber are used for animal, avian, or fish feed,and the starch is used for many purposes such as sweetener or alcoholproduction.

The process of extrusion is well known in the art. For example, the useof extrusion to promote degradation and liquefaction of starch withincereal grain to provide a feedstock for alcoholic fermentation has beenreported. The extrudate may be processed further by exposure to enzymesor heat.

While the process of extrusion is well known in the art, typically, theextruded product is not separated after extrusion. The development of aprocess that uses extrusion to facilitate separation of a cerealmaterial into various product streams would be desirable.

SUMMARY OF THE INVENTION

The present invention relates to producing a fermentation feedstock froma cereal material that is extruded, wherein the extrudate is liquefied.The liquefied extrudate is separated into two or more streams.Optionally the liquefied extrudate may be saccharified. Optionally, theprotein of one or more streams may be hydrolyzed.

The present process is further related to using the extruded, liquefied,and separated cereal material in the production of a fermentationfeedstock. Furthermore, the present process is related to using theextruded, liquefied, and separated cereal material as a fermentationfeedstock.

DETAILED DESCRIPTION OF THE INVENTION

The present invention relates to producing a fermentation feedstock froma cereal material that is extruded, wherein the extrudate is liquefied.The liquefied extrudate is separated into two or more streams.Optionally the liquefied extrudate may be saccharified. Optionally, theprotein of one or more streams may be hydrolyzed.

The present process is further related to using the extruded, liquefied,and separated cereal material in the production of a fermentationfeedstock. Furthermore, the present process is related to using theextruded, liquefied, and separated cereal material as a fermentationfeedstock.

The process described herein relates to a method for producing afermentation feedstock from an extruded cereal material. Extrusionincludes introducing the cereal material into an extruder and passingthe cereal material through the extruder. The extruder includes a diethrough which the extrudate exits. The cereal material is subjected toheat and pressure in the extruder.

The term cereal material herein may be any cereal material and includeswhole products and parts thereof. Examples of suitable cereal materialincludes material derived from corn, oats, barley, rye, wheat, rice,sorghum, other millets, or a mixture thereof.

The present process is also related to optionally treating the cerealmaterial with a fluid before and/or during extrusion. The fluid usedherein may be, water, steam, an aqueous solution, an organic solution,or mixtures thereof. Preferred for use, however, is an aqueous solution.The organic solution can be an organic solvent that is selected from thegroup consisting of hexane, isohexane, ethanol, methanol, acetone,propanol, iso-propanol, butanol and mixtures thereof. The treated cerealmaterial may then be extruded to form the extrudate.

In the present process, the cereal material may be further contactedwith an agent prior to or during extrusion. Agents suitable forcontacting the cereal material include reducing agents, enzymes, andacids. Suitable reducing agents include sulfur dioxide, salts ofsulfite, and the like. The fluid may contain enzymes that are intendedto hydrolyze particular fiber, protein, or carbohydrate. Suitableenzymes may include cellulases, hemicellulases, proteases, amylases, andglucoamylases. Examples of proteases include Bromelain. The fluid mayhave an acidic pH. Typically, the pH of the fluid may range from about 1to about 7, from about 1 to about 4 and most preferably about 1.5 toabout 2.5. Suitable acids include sulfuric acid, sulfurous acid,hydrochloric acid, a carboxylic acid, and a mixture thereof. Examples ofcarboxylic acid include acetic acid, oxalic acid, malonic acid, sucinicacid, malic acid, lactic acid, citric acid, gluconic acid, and a mixturethereof.

Processing of the corn material may be influenced by conditions withinthe extruder obvious to those skilled in the art. For example, thepressure and temperature within the barrel may be regulated. Thepressure within the barrel may be regulated by controlling the volume ofcorn material introduced into the barrel or by introducing additionalmaterial into the barrel such as an aqueous processing solution.Additionally, the pressure, residence time, and shear may be adjusted byflight, screw, and barrel configuration. The temperature within thebarrel may be adjusted to facilitate processing of the corn material aswell. Depending on the temperature and pressure differences across thedie, the surface area of the extrudate is increased to a level thatexceeds the surface area of the corn material before extrusion.

The extruder preferably has a short length, high speed, and a shortretention time. In regard to rotation speed, the extruder preferablyoperates at a speed of at least 700 RPM, and preferably greater than1000 RPMC. In regard to the extruder's dimension, the extruderpreferably has a length to diameter ratio of less than 12 and preferablyaround 5-7. During extrusion, the corn material preferably has aretention time of no more than about 10 seconds. Energy input to theextruder is commonly about 100-250 W-hr/kg (155-387 BTU/lb).

The temperature of the extruder may be regulated to control processing.For example, the cereal material may be extruded under conditions inwhich the cereal material is heated preferably to about 120° C. to 280°C. in the extruder.

Generally, the process involves extruding a cereal material to form anextrudate, which includes protein, fiber, oil, and starch. The extrudateis liquefied to form a liquefied extrudate, which includes protein,fiber, oil, and liquefied starch. The liquefied extrudate then isseparated to provide one or more streams that include a protein andfiber-containing stream and/or a liquefied starch stream. It may bedesirable to treat the liquefied extrudate to provide a saccharifiedextrudate, which includes saccharified starch. It may be also desirableto treat the liquefied extrudate to provide a degraded material, whichincludes liquefied starch material, fiber, oil, and hydrolyzed protein.The process may also involve extruding a cereal material to form anextrudate that is introduced into an aqueous liquid in a chamber. Theaqueous liquid may include an enzyme, such as alpha-amylase, and/or anacid. To promote liquefaction of the extrudate, the aqueous solution maycontain acid, base, and/or enzymes, such as a protease or an amylase.

Separation processes may be used to provide insoluble or solublestreams, for example a “liquefied starch stream” or “liquefied starchmaterial.” As defined herein, “liquefied starch stream” and “liquefiedstarch material” may be defined as amylaceous material that has at leastbeen substantially hydrolyzed and may have been further converted intosmaller oligosaccharides and/or high DE materials such as dextrose. Asdefined herein, “saccharification” refers to enzymatic conversion oflong chain or cross-linked carbohydrates into smaller oligosaccharidesby enzymes such as amylases. A measure of saccharification can beobtained by calculating the amount of free aldehyde groups relative tothe molecular weight of the sample. This is commonly characterized asthe “dextrose equivalents” or “DE” of a carbohydrate derived material.

To facilitate liquefaction, the aqueous solution within the chamber mayinclude an alpha-amylase, or the aqueous solution may have an acid pH.For example, a pH of 1.5-6.0 may be desirable. Also, where desirable,the aqueous solution within the chamber may be heated to a temperatureof at least about 80° C. to facilitate further hydrolysis of thestarch-containing material. Where the aqueous solution is in a closedchamber to allow greater than atmospheric pressures, the aqueoussolution may be heated to temperatures of up to about 150° C.

As an example of a method for producing a fermentation feedstock, thefollowing is provided. The starch comprising extrudate produced by thepreviously described extrusion processes may be optionally hydrolyzed toform a fermentation feedstock to be incorporated into the fermentationmedia. The extrudate may be hydrolyzed to any extent to form ahydrolyzed starch, including to dextrose. The extrudate slurry may behydrolyzed by any manner. For example, extrudate may be hydrolyzed bysubjecting the extrudate to acid hydrolysis. Typically acids willinclude inorganic acids such as hydrochloric acid and the like. Elevatedtemperatures increase the rate of hydrolysis and may be varied over awide range depending on the degree of hydrolysis desired. Acidhydrolysis is limited in the extent of starch hydrolysis possible. Ifone wishes to exceed that level of hydrolysis, one must use other meansof hydrolysis such as enzymatic digestion of the starch with starchhydrolyzing enzymes.

An exemplary process for carrying out starch liquefaction by acidhydrolysis is described as follows:

-   -   a) The extrudate has water added to from a 40% dry solids        solution;    -   b) the pH of the slurry is adjusted to 1.8 with 22 Baumé        hydrochloric acid;    -   c) the slurry with pH 1.8 is introduced into a converter at        295° F. for 18 minutes; and    -   d) the converted starch is then pH to 4.8 with 10% soda ash and        cooled, with a hydrolysis to 85 DE is achieved.

An exemplary process for starch hydrolysis by enzyme/enzyme hydrolysisis described as follows:

Hydrolysis of starch is performed in the following steps of 1)liquefaction and 2) optionally, saccharification.

Enzyme liquefaction: Water is added to the extrudate to adjust dry solidcontent to 35%. The pH of slurry is adjusted to 5.5 using sodiumhydroxide solution. Calcium chloride is added to the slurry to have theminimum of 5 ppm of free calcium. Termamyl Supra (TERMAMYL SUPRA™amylase enzyme, available from Novozymes North America, Inc) is added tothis pH adjusted slurry at the amount of 0.4 liter per metric ton ofstarch dry solids. Then, the mixture is heated in a continuous jetcooker to 108° C. and held for 5 minutes in a pressurized vessel. Thenthe cooked mixture is cooled to 95° C. and held for 100 minutes.Hydrolysate with a DE of 8 to 12 is achieved at this point.

The current process may also further comprise saccharifying saidliquefied starch. Saccharification: Starch hydrolysate from the aboveliquefaction step is cooled to 60° C. and the dry solid content isadjusted to 32% by adding water. The pH of this diluted hydrolysate isadjusted to 4.1-4.3 using sulfuric acid. DEXTROZYME E™ Enzyme atrademarked (mixture of amyloglucosidase and pullunase available fromNovozymes North America, Inc) is added at the amount of 0.7 liters permetric ton of dry solids and then the mixture is held for 40 hours.Dextrose content of 95-97%, on the dry solid basis, is achieved.

Further information regarding starch hydrolysis is found in Technologyof Corn Wet Milling and Associated Processes p. 217-266, Paul H.Blanchard, Elsevier Science Publishers B. V. Amsterdam.

After the cereal material has been liquefied, the liquefied material maybe separated into two or more streams; for example, a protein andfiber-containing stream and/or a liquefied starch-containing stream, andthese separated streams may be further separated to provide subsequentstreams with desirable properties. Separation may involve filtration,(for example, screening with a pressure feed screen and/or separationusing a microfilter or cloth belt), centrifugation, (that is centrifugalseparation), and/or extraction. The liquefied cereal material orseparated streams may be treated to promote hydrolysis of components.For example, the liquefied material or separated streams may be treatedwith acid, base, or enzymes such as proteases to provide hydrolyzedprotein, or amylases to provide liquefied starch or saccharified starch.

Processing of the extrudate may include separation of the liquefiedcereal material, and components thereof, into various streams. Examplesof streams include an oil-containing stream (for example, germ stream),a protein-containing stream (for example, gluten stream), astarch-containing stream, or any combination thereof. These streams maybe directed to downstream operations for further processing (forexample, production of fermentation feedstock). Alternatively thesestreams may be directed to side streams for further processing ordisposal (for example, oil extraction, production of animal feed orfermentation feedstock).

Where desirable, the protein and fiber-containing stream may beseparated to provide a protein-enriched stream and a fiber-enrichedstream, for example, by screening or centrifugation. The protein andfiber-containing stream or the protein-enriched stream may be treatedfurther to provide a hydrolyzed protein-containing stream, for exampleby treating the protein and fiber-containing stream or theprotein-enriched stream with a protease. As defined herein, “hydrolyzedprotein” may be defined as proteinaceous material that has beenpartially reduced smaller polypeptides and amino acids. The amount ofsmaller polypeptides and amino acids can be represented by measuring theamount of soluble protein within a protein solution (wt. %) at a givenpH. A measure of the free amino acid percentage within the proteinsolution can be obtained by calculating the amount of free amino groupsrelative to the molecular weight of the sample, herein defined as “FAN.”The nitrogen to FAN ratio is about 5 or less. The hydrolyzedprotein-containing stream may be combined with the saccharified materialto form a nitrogen-enriched fermentation feedstock.

In a first embodiment, the process includes extruding cereal material toform an extrudate, which includes protein, fiber and liquefied starch.Using for example corn, the corn is cleaned by passing the corn throughscreens, which removes trash and optionally broken corn and finematerial. The cleaned corn is then transferred to an extruder.

Water may be added to adjust the moisture of the corn and to modify themorphology of the extrudate. The corn material may be extruded underconditions that include contacting the corn material with an aqueoussolution to form a tempered cereal material and extruding the temperedcereal material to form the extrudate. The aqueous solution may have anacid pH, for example, a pH of about 1.0 to about 7. To obtain an acidpH, the aqueous solution may contain sulfuric acid, sulfurous acid,hydrochloric acid a carboxylic acid, or a mixture thereof. Wherecarboxylic acid is chosen, the carboxylic acid may include acetic acid,oxalic acid, malonic acid, sucinic acid, malic acid, lactic acid, citricacid, gluconic acid, and a mixture thereof. Where desirable, the cerealmaterial may be treated with sulfur dioxide or salts of bisulfite.

In this first embodiment, it may be desirable to form a liquefiedextrudate that includes protein, fiber and liquefied starch. To promoteliquefaction, the extrudate may be cut by a cutting mechanism after itpasses through the extruder and exits through a die. The temperature ofthe die is maintained at least about 120° C. and no more than about 280°C. As the extrudate passes through the die, it expands and enters anaqueous bath. The density of the extrudate is commonly about 10-200 g/L.After the extrudate has entered the aqueous solution, the aqueoussolution containing the extrudate is transferred to a first holdingvessel. To promote liquefaction of the extrudate, the aqueous solutionmay contain acid, base, and/or enzymes, such as a protease or anamylase.

After the extrudate has been liquefied to any desirable level, theliquefied extrudate is separated to provide a protein andfiber-containing stream and a starch-containing stream, for example, byfiltration with a rotary vacuum filter. The separated streams may befurther treated to provide subsequent streams with desirable properties.For example, the starch-containing stream may be treated with aglucoamylase to promote starch breakdown. The amount of starch breakdownmay be determined by calculating the DE. The saccharified material whichincludes saccharified starch and has a DE of at least about 20. Tofacilitate saccharification, the cereal material may be extruded in thepresence of a glucoamylase. Any remaining solids may be removed from thesaccharified solution, for example, by filtration through a membranefilter. It may be desirable to obtain an oil-enriched stream byextracting the remaining solids with a solvent to recover oil.

In another embodiment a second process for producing a fermentationfeedstock from cereal material is provided. The process includesextruding cereal material to form an extrudate, which includes protein,fiber, and starch. In this embodiment, the extrudate is liquefied toform a liquefied extrudate which includes protein, fiber and liquefiedstarch. The liquefied extrudate is further treated to provide a degradedmaterial which includes liquefied starch material, fiber and hydrolyzedprotein. For example, the liquefied extrudate may be treated with aprotease to hydrolyzed. Where desirable, the degraded material may beseparated to provide a solids stream, which includes fiber, and asoluble stream, which includes hydrolyzed protein and liquefied starchmaterial. The soluble stream may be saccharified to provide asaccharified stream which includes soluble protein and has a DE of atleast about 20.

In another embodiment, the liquefied extrudate is also saccharifiedbefore separating. The liquefied saccharified material has a DE of atleast about 20. Fiber is separated from the extruded, liquefied, andsaccharified material with a 5 stage screen separation system arrangedsuch that the fiber is washed in a counter current flow of fiber toclean water, where the cleanest fiber is washed with the cleanest wateradded to the screen system. Washed fiber is discharged at the last stage(fifth stage), while starch and protein containing slurry is dischargeat the first stage. The screen opening on the first fiber wash stage is50 micron, followed by 75 micron on the second, 100 micron on stages 34,and 150 micron of the last stage. The washed fiber is dewatered usingscrew presses, and dried using a rotary drier, resulting in the driedfiber product. The de-fibered stream is then treated with a protease.The protein is hydrolyzed until the nitrogen to FAN ratio is about 5 orless.

In another embodiment, a forth process for producing a fermentationfeedstock from cereal material is provided. The process includesextruding cereal material to form an extrudate, which includes protein,fiber, and starch. After extrusion, the extrudate is liquefied to form aliquefied extrudate which includes protein, fiber and liquefied starch.In this embodiment, the liquefied extrudate is separated to provide aprotein and fiber-containing stream and a liquefied starch-containingstream. The process may also include saccharifying the liquefied starchstream to provide a saccharified material which includes saccharifiedstarch and has a DE of at least about 20. To facilitatesaccharification, the cereal material itself may be extruded in thepresence of an amylase. The saccharified extrudate may then be separatedto provide a protein and fiber-containing stream and a saccharifiedstarch-containing stream.

In this embodiment, the protein and fiber-containing stream may beextracted with a solvent. The solvent selected from the group consistingof hexane, isohexane, ethanol, methanol, acetone, propanol,iso-propanol, butanol and mixtures thereof, and separating to provide anoil containing solvent stream and an oil-depleted component stream. Theoil-depleted, protein and fiber stream may be treated with a protease toform a protease-treated stream that includes hydrolyzed protein. Theinsoluble solids within this protease-treated stream may be removed toprovide a hydrolyzed protein containing stream, for example, byfiltration or centrifugation. This hydrolyzed protein containing streamthen may be combined with a portion of the saccharified material to forma nitrogen-enriched fermentation feedstock.

In this embodiment, the cereal material may be contacted steam followedby a solution containing sodium bisulfite prior to extrusion to form atempered cereal material, and the tempered cereal material then may beextruded to form the extrudate. The process may include extruding thecereal material under conditions which heat the cereal material to about120° C. to 280° C., and the process may include extruding the cerealmaterial through an extruder under conditions such that the volume ofthe cereal material expands, desirably by about 50%.

To facilitate liquefaction, the aqueous solution within the chamber mayinclude an alpha-amylase, or the aqueous solution may have an acid pH.For example, a pH of 1.5-6.0 may be desirable. Also, where desirable,the aqueous solution within the chamber may be heated to a temperatureof at least about 80° C. to facilitate further hydrolysis of thestarch-containing material. Where the aqueous solution is in a closedchamber to allow greater than atmospheric pressures, the aqueoussolution may be heated to temperatures of up to about 150° C.

In another embodiment, insoluble or soluble streams may be combined toprovide subsequent streams with desirable characteristics. For example,a hydrolyzed protein-containing stream may be combined with saccharifiedmaterial to form a nitrogen-enriched fermentation feedstock. Therelative amounts of carbohydrate and nitrogen can be represented by a“C/N” ratio. The nitrogen-enriched fermentation feedstock has a C/Nratio of about 15 or less.

The following examples are presented to illustrate the present inventionand to assist one ordinarily skilled in making and using the same. Theexamples are not intended in any way to otherwise limit the scope of theinvention.

EXAMPLES Example 1

Corn is cleaned by passing the corn through screens, which removes trashand optionally broken corn and fine material. Water, with lactic acidadded, having a pH of 3.4, adjusted with sulfuric acid, is added toadjust the moisture of the corn to 25%. The cleaned corn is thentransferred to an extruder.

In regard to rotation speed, the extruder is operated at a speed ofabout 850 RPM. In regard to the extruder's dimension, the extruder has alength to diameter ratio of about 6. Within the extruder, the cornshould have a retention time of around 5 seconds. Energy input to theextruder is about 175 W-hr/k-g (about 271 BTU/lb).

The corn is heated to about 200° C. during extrusion. As the extrudatepasses out of the die directly into an aqueous bath that includesamylase, it expands and is cut into pieces with a submerged cuttermounted on the end of the die. The density of the extrudate is about 55g/L.

The extrudate is transferred to a holding vessel. Water is added to theextrudate to adjust dry solid content to 35%. The pH of slurry isadjusted to 5.5 using sodium hydroxide solution. Calcium chloride isadded to the slurry to have the minimum of 5 ppm of free calcium.TERMAMYL SUPRA enzyme, (a trademarked amylase available from NovozymesNorth America, Inc) is added to this pH adjusted slurry at the amount of0.4 liter per metric ton of starch dry solids. The mixture is allowed tocooled to 95° C. (203° F.) and held for 100 minutes. Starch moleculebreakdown in the vessel occurred such that the DE level reached 8. Theaqueous solution is separated from the coarse solids by passing theaqueous solution through a series of five pressure feed screen withabout 75 micron slots. Fresh or cycled aqueous solution flows countercurrently to the fiber to increase recovery of aqueous solution. Thecoarse solids are retained and dried, and the clarified aqueous solutionis passed to a second holding vessel. The clarified aqueous solution iscooled to 60° C. and the dry solid content is adjusted to 32% by addingwater. The pH of this diluted hydrolysate is adjusted to 4.1-4.3 usingsulfuric acid. DEXTROZYME E enzyme (a trademarked mixture ofamyloglucosidase and pullunase available from Novozymes North America,Inc) is added at the amount of 0.7 liters per metric ton of dry solidsand then the mixture is held for 40 hours. Dextrose content of 95-97%,on the dry solid basis, is achieved. The saccharified solutioncontaining dextrose then is clarified of remaining solids using amembrane filter. The sacrharified solution is retained for afermentation feedstock. The retentate from the membrane filtering istreated with an protease to hydrolyze the protein. The hydrolyzedsolution is then separated from the solids on a rotary vacuum filter.The solids from the rotary vacuum filter are combined with the driedfiber. The dried solids then are extracted with a solvent to recoveroil. The hydrolyzed protein stream is retained for a fermentationfeedstock.

Example 2

Corn is extruded as in Example 1. The extrudate is discharged into anaqueous bath containing proteases, and the aqueous solution is passed toa holding tank. After the proteins have been hydrolyzed to a level wherethe total nitrogen to FAN ratio of no more than about 5. Any insolublesolids including insoluble protein and fiber are separated from theaqueous solution by filtering the solution through screens as inExample 1. As in Example 1, additional aqueous solution is recovered byrinsing the insoluble solids through stage rinses on pressure feedscreens with fresh or cycled aqueous solution. The insoluble solids aredried and retained.

Glucoamylase is then added to the clarified aqueous solution, and theaqueous solution is then saccharified until the level of reducing sugarsreaches 80%.

Example 3

The process of example 1 is followed except that wheat is substitutedfor the corn. It is expected that similar results will be obtained.

Example 4

Corn are extruded as in Example 1. The extrudate is discharged directlyinto an aqueous bath containing amylase, and the aqueous solutioncontaining the extrudate is passed to a holding vessel until starchmolecule breakdown in the vessel occurred such that the DE level reached8. Glucoamylase is then added and the material is saccharified. Afterthe material has been saccharified until the level of reducing sugarsreaches 95%, a protease is added to hydrolyze the protein to amino acidand polypeptides, until the FAN level is about 4. After the desiredlevel of protein breakdown has occurred, insoluble solids are separatedfrom the aqueous solution by filtering the material with a rotary vacuumfilter.

Example 5

Corn is extruded as in Example 1. The extrudate is discharged into anaqueous bath containing amylase. The extrudate is transferred to aholding vessel and liquefied as in Example 1. After starch hydrolysis inthe vessel occurred such that the DE level reached 10, the aqueoussolution is separated from the course solids as in Example 1.Glucoamylase is added to the clarified aqueous solution, and thesolution is saccharified until the level of reducing sugars reaches 90%.

The solids are separated by with a Merco H36 centrifuge. This centrifugeoperates at 2600 rpm and is fitted with No. 24 size nozzle. Theunderflow, containing an concentrated protein stream is placed into aholding tank containing an aqueous solution of protease. After theproteins have been hydrolyzed to a level where the total nitrogen to FANratio of no more than about 5, the aqueous solution and remaining solidsare separated as in Example 1. The clarified, amino acid and polypeptidesolution is then retained for fermentation. The removed solids are driedand optionally extracted with solvent to recover oil. A portion of thesaccharified solution is combined with a portion of the hydrolyzedprotein stream to have a C/N ratio of about 14.

The method has been described with reference to various specificembodiments and techniques. The examples described herein illustrate butdo not limit the scope of the invention that has been set forth herein.It should be noted that the description of various embodiments providedin the this disclosure may be of overlapping scope. The embodimentsdiscussed in this disclosure are merely illustrative and are not meantto limit the scope of the present invention, or equivalents thereof. Itshould be understood that many variations and modifications may be madewhile remaining within the spirit and scope of the invention.

1. A process for treating a cereal material comprising: extruding thecereal material to form an extrudate comprising starch and a componentselected from the group consisting of protein, fiber, and a mixturethereof; liquefying the starch in the extrudate; and separating theextrudate into at least two or more streams comprising one or morecomponents selected from a group consisting of liquefied starch, oil,protein, fiber, and mixtures therefore.
 2. The process of claim 1further comprising saccharifying said liquefied starch.
 3. The processof claim 2 wherein the liquefied starch is saccharified prior toseparation.
 4. The process of claim 1 further comprising hydrolyzingprotein.
 5. The process of claim 1, wherein at least one of said streamscomprises liquefied starch and protein, and further comprisingsaccharifying said liquefied starch and hydrolyzing said protein.
 6. Theprocess of claim 2 further comprising hydrolyzing protein of a proteincontaining stream and combining at least a portion of the hydrolyzedprotein and at least a portion of the saccharified starch.
 7. Theprocess of claim 2 wherein the saccharified starch has a DE of at leastabout
 20. 8. The process of claim 3 wherein the saccharified starch hasa DE of at least about
 20. 9. The process of claim 4 wherein the proteinis hydrolyzed with a protease.
 10. The process of claim 6 wherein thehydrolyzed protein has a total nitrogen to FAN ratio not greater thanabout
 5. 11. The process of claim 1 wherein the extruding of the cerealmaterial comprises passing the cereal material through an extruder thatoperates at a speed of at least 700 RPM with an energy input to theextruder of about 100-250 W-hr/kg; wherein the extruder has a length todiameter ratio of no more than about 12, and wherein the cereal materialis retained in the extruder for no more than about 10 seconds.
 12. Theprocess of claim 1 wherein the cereal material is extruded in thepresence of an acid.
 13. The process of claim 12 wherein the acid isselected from the group consisting of sulfuric acid, sulfurous acid,hydrochloric acid, a carboxylic acid, and a mixture thereof.
 14. Theprocess of claim 13 wherein the carboxylic acid is selected from thegroup consisting of acetic acid, oxalic acid, malonic acid, sucinicacid, malic acid, lactic acid, citric acid, gluconic acid, and a mixturethereof.
 15. The process of claim 1 wherein the cereal material isextruded in the presence of an amylase.
 16. The process of claim 1wherein the cereal material is extruded at a temperature from about 120to about 280° C.
 17. The process of claim 1 wherein the cereal materialis contacted with a fluid selected from a group consisting of water,steam, or an aqueous solution.
 18. The process of claim 1 wherein thecereal material is contacted with sulfur dioxide and or salts ofsulfite.
 19. The process of claim 17 wherein the cereal material iscontacted with an aqueous solution having a pH of less than
 7. 20. Theprocess of claim 1 further comprising contacting a component selectedfrom the group consisting of fiber, oil, protein, starch, and mixturesthereof with a solvent selected from the group consisting of hexane,isohexane, ethanol, methanol, acetone, propanol, iso-propanol, butanoland mixtures thereof, and separating the stream to provide an oilcontaining stream and an oil-depleted stream.
 21. A fermentationfeedstock product produced in accordance with the process of claim 1having a carbon to nitrogen ratio not greater than about
 15. 22. Afermentation feedstock product produced in accordance with the processof claim 4 having a carbon to nitrogen ratio not greater than about 15.23. A fermentation feedstock product produced in accordance with theprocess of claim 5 having a carbon to nitrogen ratio not greater thanabout
 15. 24. A process for producing a fermentation feedstockcomprising using the product of claim
 1. 25. A process for producing afermentation feedstock comprising using the product of claim
 8. 26. Aprocess for using the product of claim 24 as a fermentation feedstock.27. A process for using the product of claim 25 as a fermentationfeedstock.
 28. A fermentation feedstock produced according to claim 24.29. A fermentation feedstock produced according to claim
 25. 30. Theprocess according to claim 20 further comprising recovering an oilproduct from the oil containing stream.